Media purification devices having intergral flow controllers

ABSTRACT

A purification device is provided that includes a porous container, purification media retained in the porous container, and a flow controller integral to the porous container. A purification device is also provided that includes a porous elastic container, purification media, and a flow controller. The porous elastic container has a pocket formed therein. The purification media is compressibly retained in the porous elastic container. The flow controller is elastically retained in the pocket of the porous elastic container.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No. 15/914,049filed on Mar. 7, 2018, which claims the benefit of U.S. ProvisionalApplication Ser. No. 62/468,167 filed on Mar. 7, 2017 and claims thebenefit of U.S. Provisional Application Ser. No. 62/628,923 filed onFeb. 9, 2018. U.S. application Ser. No. 15/914,049 filed on Mar. 7, 2018is also a continuation of U.S. application Ser. No. 14/684,071 filed onApr. 10, 2015, which claims the benefit of U.S. Provisional ApplicationSer. No. 61/977,778 filed Apr. 10, 2014 and claims the benefit of U.S.Provisional Application Ser. No. 62/065,803 filed Oct. 20, 2014. Thecontents of all of which are incorporated by reference herein in theirentirety.

BACKGROUND 1. Field of the Invention

The present disclosure is related to media purification devices. Moreparticularly, the present disclosure is related to media purificationdevices having integral flow controllers.

2. Description of Related Art

The use of pure water in various cleaning applications is well known.One common cleaning application for pure water is the cleaning ofwindows, cars, buildings, solar panels, and other surfaces. For example,the use of pure water in the form of deionized (DI) water, also known asdemineralized (DM) water, has been found to be particularly effectivewhen cleaning smooth or reflective surfaces such as metal, glass,ceramics, tile, marble, plastics, and others. The pure water can reducethe formation water marks and spots, which can be formed by impuritiesin untreated water that remain on the surface when the water dries.

Many pure water systems use one or more types of purification mediaalone or in combination with other devices/processes such as, but notlimited to, particle filtration, distilling (i.e., distilled water),reverse osmosis, desalination, carbon filtration, microfiltration,ultrafiltration, ultraviolet oxidation, electrodialysis, others, and anycombinations thereof.

Some pure water systems improve the ease of replacing depleted or spentpurification media by providing media purification devices that containor house the purification media.

Such pure water systems and purification media devices are described inApplicant's own U.S. patent application Ser. Nos. 14/684,071;29/594,840; 29/544,787; 29/487,620; and Ser. No. 29/487,621, the entirecontents of which are incorporated herein by reference.

It has now been determined that there is a continuing need for mediapurification devices that improve the efficiency and provide forincreased utilization of the purification media.

SUMMARY

A purification device is provided that includes a purification mediacontained within an porous container, which in some embodiments iselastic and/or non-elastic. The device includes an integral flowcontroller, which is configured to ensure maximized resin utilization.

In other embodiments, the integral flow controller is configured toprovide additional back pressure and/or restrictions to flowinto/through the purification media as a result of the fluid flowthrough the device.

In some embodiments, the integral flow controller is in an interior ofthe porous container—elastic and/or non-elastic. Here, the flowcontroller is considered to be integral with the container by virtue ofit residing within the container. Moreover, in some embodiments, theflow controller can be connected to the interior of the container.

The flow controller—when integral with the interior—can be positioned ata lower interior surface of the media device, with respect to the flowdirection, at an upper interior surface, at any location between theupper and lower surfaces, or any combinations thereof.

The integral flow controller—when integral with the interior—can be arigid member, a flexible member, or combinations of rigid and flexible.For example, in some embodiments, the flow controller can have aflexible outer rim that conforms to imperfections in the system and arigid central portion.

The integral flow controller—when integral with the interior—can includea pivot preventer, which is configured to maintain the controllersubstantially perpendicular to the primary flow axis. In someembodiments, pivot preventer includes a number of upstanding edges, withthe pivot preventer facing the media in the porous container. In otherembodiments, pivot preventer is a continuous or non-continuous rim thatfaces the media in the container.

In other embodiments, the integral flow controller forms a part of theelastic porous container. For example, the flow controller can be anelastic polymer cured on the porous elastic container in a manner thatprovides a flow pattern through the media. In other examples, the flowcontroller can be embossed stitching, patches, stickers, paint,printing, or any other structure of the porous elastic container thathas a lower porosity than the remaining regions of the porous elasticcontainer so as to provide the desired media utilization.

In other embodiments, the integral flow controller forms a part of thematerial of the elastic porous container. Here, the flow controller isconsidered to be integral with the elastic porous container by virtue itforming part of the elastic porous container. For example, the flowcontroller can be joined (e.g., sewn, adhered, welded, held, connected,etc.) into an opening in the porous elastic container in a manner thatprovides the desired media utilization.

A purification device is provided that includes a porous container,purification media retained in the porous container, and a flowcontroller integral to the porous container.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the porous containeris an elastic porous container and the purification media iscompressibly retained in the elastic porous container.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the flow controlleris completely inside the porous container.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the flow controlleris completely outside the porous container.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the flow controlleris partially inside and partially outside the porous container.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the flow controlleris at a water entry side of the porous container and/or at a water exitside of the porous container.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the flow controlleris connected to an interior of the porous container.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the flow controlleris connected to an interior surface of the porous container at a waterentry side of the porous container and/or at a water exit side of theporous container.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the flow controlleris a rigid member, a flexible member, or combinations thereof.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the flow controlleris made of a material selected from the group consisting ofpolypropylene (PP), acrylonitrile butadiene styrene (ABS), polystyrene(PS), polyvinyl chloride (PVC), thermoplastic elastomer (TPE), stainlesssteel, and any combinations thereof.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the flow controllerhas a pivot preventer configured to maintain the flow controllerperpendicular to a primary flow axis (A).

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the flow controllerforms a part of the porous container.

A purification device is also provided that includes a porous elasticcontainer, purification media, and a flow controller. The porous elasticcontainer has a pocket formed therein. The purification media iscompressibly retained in the porous elastic container. The flowcontroller is elastically retained in the pocket of the porous elasticcontainer.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the pocket is in aninner surface of the porous elastic container.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the pocket is in awater entry side of the porous elastic container, at a water exit sideof the porous container, or at both the entry and exit sides of theporous container.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the flow controllerstretches the water entry side of the porous elastic container at least10% and/or stretches the water exit side of the porous elastic containerat least 10%.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the flow controllerhas a frustoconical shape that tapers upward from the water entry side.

A pure water system is also provided that includes a tank, a cover, aninlet port, and an outlet port configured to define a reservoir. Thesystem includes a purification device received in the reservoir so thatwater can flow into the inlet port, through the purification device, andout of the outlet port a primary axis of flow (A). The purificationdevice includes a porous container, purification media retained in theporous container, and a flow controller integral to the porouscontainer.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the porous containeris a porous elastic container.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the flow controllerstretches the water entry side of the porous elastic container at least10%.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the primary axis offlow is an upward flow direction.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the flow controlleris at a water entry side of the porous container, the water entry sidebeing proximate the inlet port.

A method of purifying water is also provided. The method includespassing water through a porous container, the porous container havingpurification media retained therein and having a flow controllerintegral to the porous container, wherein the water passes through thepurification media and the flow controller.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the step of passingthe water through the porous container comprises passing the waterthrough an elastic porous container with the purification mediacompressibly retained therein.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the step of passingthe water through the porous container comprises passing the waterthrough the flow controller that is completely inside the porouscontainer, completely outside the porous container, or partially insideand partially outside the porous container.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the step of passingthe water through the porous container comprises passing the waterthrough the flow controller at a water entry side of the porouscontainer and/or at a water exit side of the porous container.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the step of passingthe water through the porous container comprises passing the waterthrough the flow controller that is connected to an interior of theporous container.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the step of passingthe water through the porous container comprises passing the waterthrough the flow controller that is a rigid member, a flexible member,or combinations thereof.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the step of passingthe water through the porous container comprises passing the waterthrough the flow controller that is made of a material selected from thegroup consisting of polypropylene (PP), acrylonitrile butadiene styrene(ABS), polystyrene (PS), polyvinyl chloride (PVC), thermoplasticelastomer (TPE), stainless steel, and any combinations thereof.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the step of passingthe water through the porous container comprises passing the waterthrough the flow controller that has a pivot preventer configured tomaintain the flow controller perpendicular to a primary flow axis (A).

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the step of passingthe water through the porous container comprises passing the waterthrough the flow controller that forms a part of the porous container.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the step of passingthe water through the porous container comprises passing the waterthrough the flow controller that is elastically retained in a pocket ofthe porous elastic container.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the step of passingthe water through the porous container comprises passing the waterthrough the flow controller elastically retained in the pocket, thepocking being in an inner surface of the porous elastic container, beingthe pocket is in a water entry side of the porous elastic container,being at a water exit side of the porous container, or at both the entryand exit sides of the porous container.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the step of passingthe water through the porous container comprises passing the waterthrough the flow controller elastically retained in the pocket, wherethe flow controller stretches the a portion of the porous elasticcontainer at the pocket by at least 10%—the portion being at a waterentry side and/or a water exit side of the porous elastic container.

In some embodiments either alone or together with any one or more of theaforementioned and/or after-mentioned embodiments, the step of passingthe water through the porous container comprises passing the waterthrough the flow controller elastically retained in the pocket, wherethe flow controller has a frustoconical shape that tapers upward fromthe pocket.

The above-described and other features and advantages of the presentdisclosure will be appreciated and understood by those skilled in theart from the following detailed description, drawings, and appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The patent or application file contains at least one photograph executedin color. Copies of this patent or patent application publication withcolor photograph(s) will be provided by the Office upon request andpayment of the necessary fee

FIG. 1 is a schematic depiction of an exemplary embodiment of a waterpurification device according to the present disclosure in use with aprior art pure water system;

FIG. 2 illustrates a side view of an exemplary embodiment of a waterpurification device according to the present disclosure when resting ona surface;

FIG. 3 is a partial side view of the water purification device of FIG. 2when suspending by the closure;

FIG. 4 is a top view of the water purification device of FIG. 2 whenresting on a surface;

FIGS. 5 through 8 illustrate exemplary embodiments of flow controllersfor use with the water purification device according to the presentdisclosure;

FIG. 9 provides a performance comparison of different embodiments flowcontrollers according to the present disclosure;

FIG. 10 is a schematic depiction of a prior art water purificationdevice in use with a prior art pure water system;

FIG. 11 is a schematic depiction of a water purification deviceaccording to the present disclosure in use with a prior art pure watersystem when the purification media is fresh;

FIG. 12 is a schematic depiction of the water purification device ofFIG. 11 when the purification media is spent;

FIG. 13 is a schematic depiction of another embodiment of a waterpurification device according to the present disclosure in use with aprior art pure water system when the purification media is fresh;

FIG. 14 is a schematic depiction of the water purification device ofFIG. 13 when the purification media is spent;

FIG. 15 is a top partially sectioned perspective view of anotherexemplary embodiment of a water purification device according to thepresent disclosure;

FIG. 16 is a bottom, perspective view of an exemplary embodiment of aflow controller according to the present disclosure for use with thewater purification device of FIG. 15;

FIG. 17 is a side view of the flow controller of FIG. 16;

FIG. 18 is a bottom view of the flow controller of FIG. 16;

FIG. 19 is a top view of the flow controller of FIG. 16;

FIG. 20 is a side schematic view of the water purification device ofFIG. 15;

FIG. 21 is a sectional view of the water purification device of FIG. 20,taken along section A-A;

FIG. 22 is a sectional view of the container of FIG. 15 before fillingwith resin and before closing;

FIG. 23 is an enlarged view of a bottom seam of the container of FIG.22;

FIG. 24A-24G are images of a resin usage test using a prior art waterpurification device;

FIG. 25A-25G are images of a resin usage test using another prior artwater purification device;

FIG. 26A-26G are images of a second resin usage test using the waterpurification device of FIGS. 15-23; and

FIG. 27 is a data table of the results of the resin usage tests.

DETAILED DESCRIPTION

Referring to the drawings and in particular to FIGS. 1 and 2, exemplaryembodiments of a purification media device 10 according to the presentdisclosure is shown—by way of example—in use with a pure water system20.

Advantageously, purification device 10 includes a purification media 12contained within porous container 14 and has an integral flow controller16, which is configured to provide a desired media utilization. Simplystated, purification device 10 having integral flow controller 16 isconfigured to maximize the utilization of media 12 by providing one ormore of a flow pattern, compressive forces, increase a length (L) ofcontact between container 14 and tank 24, and other benefits.

As used herein, the term “integral” shall mean that device 10 has orcontains the parts that allow the device to be considered to be acomplete unit—where the parts to allow the device to be consideredcomplete include at least media 12, container 14, and controller 16.

Device 10 can be configured in many different ways so as to beconsidered “integral” within the scope of the present application. Forexample, device 10 can have controller 16 internal to container 14—withthe controller either secured to the container or not. Device 10 canhave controller 16 with at least a portion attached or secured to anexternal portion of container 14. Device 10 can have controller 16secured to container 14—internal and/or external to the container—sothat at least a portion of the controller forms a portion of thecontainer. Device 10 can have controller 16 formed directly on a surfaceof container 14—an internal and/or external surface. Device 10 can havecontroller 16 embedded in container 14—an internal and/or externalsurface. Moreover, device 10 can have any combinations of theaforementioned structures so as to be considered to have an integralcontroller within the scope of the present application.

In some embodiments, container 14 includes a closure 18 securing themedia 12 in the container. In this and/or other embodiments, container14 can be a porous elastic container. Container 14—when elastic—may beformed by a material formed from a combination of elastane and Nylon. Insome such embodiments, container 14 may be formed from a material thathas 5%-25% elastane and 75%-95% Nylon, preferably a material formed frombetween 10%-20 elastane and between 80%-90% Nylon, or with 15% elastaneand 85% Nylon being desired, and any subranges therebetween. Forexample, it is contemplated by the present disclosure for container 14to be a porous elastic bag.

Of course, it is contemplated by the present disclosure for purificationdevice 10 to find use with other systems. For example and although notshown for purposes of clarity, it is contemplated by the presentdisclosure for purification device 10 to find use with other systems 20that include other purification devices and/or processes for example,paper filters, membranes, carbon filters, and others.

It should also be recognized that purification device 10 is discussed asbeing used to treat or condition water by removing one or morecomponents from the water. Of course, it is also contemplated by thepresent disclosure for purification device 10 to treat or conditionwater or any other fluid, as well as to treat or condition by adding oneor more components such as, but not limited to, elements, compounds,ions, and others.

Therefore, as used herein, the terms “pure”, “purified”, and“purification” shall include the removal of one or more componentsand/or the addition of one or more components from water or any otherfluid. The components removed or added can include soluble and/orinsoluble materials such as, but not limited to minerals, salts,suspended particles, bacteria, and others, where the soluble componentsare often referred to as total dissolved solids or TDS.

In the illustrated embodiment, purification device 10 is shown in usewith system 20, which includes a base 22, a tank 24, and a cover 26.System 20 has a first or inlet port 28 and a second or outlet port 30.In this manner, system 20 configured to define a reservoir between firstand second ports 28, 30 in which purification device 10 is received.

During use, a pressurized water source (not shown) is fluidly connectedto first port 28 and a water using device (not shown) is fluidlyconnected to second port 30. In this manner, water flows into system 20at first port 28, through purification device 10 along a primary axis offlow (A), and out of the system at second port 30 to the water usingdevice.

In an exemplary embodiment, the pressurized water source is a normalresidential or commercial water source having a pressure ofapproximately 40 to 60 pounds per square inch (psi). Of course, it iscontemplated by the present disclosure for purification device 10 tofind use with any pressurized water source such as, but not limited to,pumped systems and at any desired pressure. Further, it is contemplatedfor purification device 10 to be configured for use with a heated fluidsource (not shown) such as, but not limited to, heating ventilation andair conditioning (HVAC) systems.

For ease of discussion, purification device 10 is described above by wayof example only having an upward flow direction—namely with thepressurized source of water connected to first port 28 located at thebottom of system 20. Of course, it should be recognized thatpurification device 10 finds equal use with the pressurized source ofwater connected to second port 30—namely with a reversed flow to thatillustrated.

A first exemplary embodiment of purification device 10 is shown in FIGS.3 through 5. Here, purification device 10 is shown having flowcontroller 16 interior to container 14.

Flow controller 16 is considered to be integral with container 14 byvirtue of the controller residing within the container. In someembodiments, flow controller 16 can be connected to the interior ofcontainer 14 at a specific position. The specific position of controller16 can be at a lower interior surface of container 14, with respect tothe flow direction, as in FIG. 3.

Of course, it is contemplated by the present disclosure for the specificposition of controller 16 to be at an upper interior surface (not shown)of container 14, at any location between the upper and lower surfaces,and any combinations thereof.

Flow controller 16—when integral with the interior of container 14—canbe a rigid member, a flexible member, or combinations of rigid andflexible. For example, in some embodiments, flow controller 14 can havea flexible outer rim that conforms to imperfections in the system 20 anda rigid central portion.

Flow controller 16—when integral with the interior of container 14—caninclude a pivot preventer 32 as shown in FIG. 6, which is configured tomaintain the controller substantially perpendicular to the primary flowaxis (A). In some embodiments, pivot preventer 32 includes a number ofupstanding edges 34, with the pivot preventer facing media 12 incontainer 14. In other embodiments as shown in FIG. 7, number ofupstanding edges 34 can further include a partial rim 36, with the pivotpreventer facing media 12 in container 14. In still other embodiments,pivot preventer 32 can simply have rim 36—where the rim can bediscontinuous or continuous around controller 16 (not shown) and wherethe rim that faces media 12 in container 14. In still furtherembodiments as shown in FIG. 8, pivot preventers 32 can be a pluralityof pairs of edges 34 that further provide a channel for fluid throughmedia 12.

In some embodiments, it is contemplated by the present disclosure forflow controller 16 to form a part of container 14. For example, flowcontroller 16 can be an elastic polymer cured on container 14 (i.e.,interior and/or exterior) in a manner that provides the desired mediautilization. In other examples, flow controller 16 can be embossedstitching, patches, stickers, paint, printing, or any other structure oncontainer 14 that has a lower porosity than remaining regions of thecontainer that do not have the flow controller so as to provide thedesired media utilization. In other embodiments, flow controller 16 canbe joined (e.g., sewn, adhered, welded, etc.) into an opening (notshown) in container 14 in a manner that provides the desired mediautilization.

Flow controller 16 can be made of any desired material sufficient toprovide the desired media utilization. For example, flow controller 16can be made of materials such as, but not limited to, polypropylene(PP), acrylonitrile butadiene styrene (ABS), polystyrene (PS), polyvinylchloride (PVC), thermoplastic elastomer (TPE), stainless steel, others,and combinations thereof.

Referring now to FIG. 9, a performance comparison of purificationdevices 10 having three different embodiments flow controllers 16according to the present disclosure as compared to a base line using aprior art purification device without any integral flow controller. Theflow controllers used are illustrated in FIG. 9 and are labeled as flowcontroller 2, flow controller 3, and flow controller 4.

The open area of the three flow controllers 16 were varied. In eachtest, water having a total dissolved solid (TDS) level of 115 parts permillion (ppm) was passed through system 20 at a flow rate of 1.5 gallonsper minute (gpm) or 5.68 liters per minute (LPM) until water exiting thesystem was measured to have TDS level above 20 ppm. During the test,measurements of the TDS of the incoming water and the gallons of waterprocessed were taken to calculate a number of grains of solids removed.Here, the term “grains” is one known unit for measuring TDS with 1 beingdefined as of 1 milligram dissolved in 1 liter of water. For ease ofcomparison, the results are reported in both liters of water and grains.

A comparison of the grains or removal efficiency and the litersprocessed of the purification devices 10 having the three different flowcontrollers 16 illustrated in FIG. 9 were then compared to the baseline.Here, it can be seen that efficiency improvements of between 15% and 19%over the baseline were achieved.

FIG. 10 illustrates the use of the prior art purification device 38without any integral flow controller in system 20. Here, system 20includes stationary or fixed upper and lower diffuser plates 40, 42. Ofcourse, it is contemplated by the present disclosure for purificationdevice 10 to find equal use with system 20 that includes no diffuserplates, only upper plate 40, only lower plate 42, and with upper andlower diffuser plates of the same or different construction. Moreover,it is contemplated by the present disclosure for upper plate 40 and/orlower plate 42 to include or lack the filter membrane or mesh of thoseprior art devices. Without wishing to be bound by any particular theory,it is believed by the present disclosure that the prior art purificationdevice 38 results in gaps 44 forming in all corners of tank 24. Gaps 44reduce a length of contact (L) between the purification device 38 andtank 24.

FIGS. 11 and 12 are schematic depictions of purification device10—having integral flow controller 16 inside of container 14 at thebottom of the container—in use with system 20 when purification media 12is fresh (FIG. 11) and spent (FIG. 12). Here, it can be seen that thevolume of media 12 decreases as the media is consumed or spent.Advantageously, flow controller 16 is believed to prevent or mitigategaps 44 (FIG. 10) from forming at the bottom of the container.Elimination or mitigation of gaps 44 increases the length of contact (L)between the purification device 10 and tank 24 as compared to the priorart.

Further and when used in combination with fixed upper and lower diffuserplates 40, 42, flow controller 16 is believed to allow a distributioncavity 46 to form between diffuser plate 42 and flow controller 16 tofurther improve distribution of water through purification device 10.

FIGS. 13 and 14 are schematic depictions of purification device10—having integral flow controller 16 inside of container 14 at both thetop and bottom of the container—in use with system 20 when purificationmedia 12 is fresh (FIG. 13) and spent (FIG. 14). Here, it can be seenthat the volume of media 12 decreases as the media is consumed or spent.Advantageously, flow controller 16 is believed to prevent or mitigategaps 44 (FIG. 10) from forming at the bottom and top of the container.Elimination or mitigation of gaps 44 further increases the length ofcontact (L) between the purification device 10 and tank 24 as comparedto the prior art.

Further and when used in combination with fixed upper and lower diffuserplates 40, 42, flow controller 16 is believed to allow a distributioncavity 46 to form between diffuser plate 42 and flow controller 16 tofurther improve distribution of water through purification device 10.

Accordingly, purification device 10 of the present disclosure—namelymedia 12, container 14, and integral flow controller 16—has been foundto provide a simple, yet effective way to improve the utilization of themedia while remaining easy to load and unload from system 20.

Referring now to FIGS. 15-23, another exemplary embodiment of apurification media device 110 according to the present disclosure isshown. Here, component parts performing similar or analogous functionsare labeled in multiples of 100 to the prior embodiments.

Purification device 110 includes purification media 112 contained withinporous container 114 and has integral flow controller 116. In someembodiments, container 114 includes closure 118 securing the media 112in the container. In other embodiments, porous container 114 is anelastic porous container. Device 110 is shown in FIG. 15 with lowerportions of container 114 shown as partial cross section to allowviewing of controller 116.

As discussed above, device 110 having integral flow controller 116maximizes the utilization of media 112 by providing one or more of aflow pattern, compressive forces, increase a length (L) of contactbetween container 114 and tank 24, a desired porosity at the waterentrance side of container 114, a desired stretch of container 114regardless of the volume or depletion amount of media 112, fit of outerdiameter of flow controller 116 to inner diameter of tank, and otherbenefits.

Flow controller 116 is considered to be integral with container 114 byvirtue of the controller residing within the container at a lowerinterior surface of container 114, with respect to the flow direction.Of course, it is contemplated by the present disclosure for the specificposition of controller 116 to be at an upper interior surface ofcontainer 114, at both the upper and lower surfaces, at any locationbetween the upper and lower surfaces, and any combinations thereof.

Controller 116 is contemplated for use with systems including fixedupper and lower diffuser plates 40, 42 for at least the reasonsdiscussed above—as well as with systems having no diffuser plates orfixed diffuser plates at only the upper or only lower positions.

While device 110 can find use with any of the flow controllers disclosedhere, an exemplary embodiment of a flow controller 116 for use withdevice 110 is shown in FIGS. 16-19.

Controller 116 has a generally frustoconical shape tapering upward froma lower outer edge 150. Controller 116 has an upper face 152 and a lowerface 154 and, may be installed in device 110 so that lower face 154 istowards the direction of flow (A).

In some embodiments, controller 116 has a central opening 156 such thatthe controller tapers from outer edge 150 to edge 158 of the opening.Central opening 156 can have an inner diameter (located at edge 158)that may be between 10% and 90% of the outer diameter (located at edge150) of the controller, may be between 20% and 60%, or with about 30% to50% being desired, and any subranges therebetween.

Controller 116 can include one or more ribs 160 defined on lower face154. Ribs 160 can provide structural rigidity to controller 116 and/orcan guide the flow of water into/through central opening 156. It isnoted that controller 116 lacks any pivot preventers discussedabove—whereas it has been determined that, in some embodiments—theintegral nature and shape of the controller 116 is sufficient tomaintain the controller substantially perpendicular to the primary flowaxis (A).

Additionally, controller 116 can include a plurality of openings 162—inthe form of slots and/or holes—at any desired location or pattern toprovide the desired flow through device 110.

In this manner, controller 116 multiple zones of differing flowrestriction. For example, central opening 156 can be thought of as azone of very low flow restriction through controller 116, while theremaining portions of the controller can be thought of as zones ofhigher levels of flow restriction as compared to the zone of the centralopening. Further when controller 116 includes openings 162, this areacan be thought of as a zone of a middle level of flow restrictionthrough the controller as compared to the zone of opening 156. Finally,controller 116 can include regions that lack any openings 162 in theregion proximate outer edge 150 can be thought of a zone of highestlevel of restriction. Simply stated, controller 116 has at least two,but in some embodiments may have at least three zones of differing flowrestriction—where the center of the controller has the lowest level ofrestriction (i.e., offers the highest level of flow) and outer edge 150of the controller has the highest level of restriction (i.e., offers thelowest level of flow).

It should be recognized that controller 116 is described above by way ofexample only as having zones of flow restriction that are lowest in thecenter and highest at the outer edge 150. Of course, it is contemplatedby the present disclosure for controller 116 to have any desired orderor number of zones that are configured to control the flow of fluidinto/through media 112 so as to improve the utilization of the mediataking into account one or more variables such as, but not limited to,tank inner diameter, tank aspect ratio, number of tank sections,flowrate, media type, TDS of incoming and/or outgoing water, and others.

In some embodiments where controller 116 is configured for use withsystem 20—which has an internal diameter of 200 mm, the controller canhave an outer diameter at edge 150 of between 160 mm and 240 mm, orbetween about 180 mm to 200 mm, with 192.5 mm being desired, and anysubranges therebetween. In this manner, controller 116 has outerdiameter that is within ±20%, or within −10% to 0%, with about −4% ofthe inner diameter of the system being desired, and any subrangestherebetween. In embodiments where controller 116 has an outer diameterthat is larger than the inner diameter of system 20, the controller canhave one or more resiliently flexible outer regions that are deformedwhen installed in the system.

In some embodiments, controller 116 can be in the form of a split ring,namely include a slit 116-1 running through the controller from edge 150to edge 158 that allows the controller to be resiliently compressed to asmaller outer diameter for securement in container 114. Here, one ormore edges of slit 116-1 can include a feature (e.g., a tongue andgroove feature) that, when engaged, prevents compression of controller116 to the smaller diameter once installed in container 114.

It should be recognized that controller 116 is disclosed without theneed for pivot preventers 32 discussed above. However, it iscontemplated by the present disclosure for controller 116 to have any ofthe features disclosed above with respect to controller 16—or forcontroller 16 to have any of the features disclosed with respect tocontroller 116.

Container 114 and the interaction between the container and controller116 is described in more detail with reference to the exemplaryembodiment illustrated in FIGS. 20-23. Here, container 114 isillustrated having a three-piece construction that includes acylindrical wall panel 164, a circular bottom panel 166, and a retainingpanel 168.

Panels 164, 166, 168 may be formed of a porous material that isresilient or elastomeric and may be made of the same material. However,it is contemplated by the present disclosure for panels 164, 166, 168 tobe made of different materials with—for example different porosityand/or elasticity.

Cylindrical wall panel 164 lacks any seams that run along the primaryflow direction (A)—namely from the bottom to the top of the container.Bottom panel 166 and cylindrical wall panel 164 are secured to oneanother along an internal seam 170. In some embodiments, internal seam170 is formed by polyester yarn (not shown). Of course, it iscontemplated by the present disclosure for internal seam 170 to be anydesired joining method such as, but not limited to, welds, adhesives,and others. Regardless of how formed, seam 170 may be provided in amanner that allows container 114 to remain elastic at the seam.

In the illustrated embodiment, bottom panel 166, cylindrical wall panel164, and seam 170 are configured, via the materials, shapes, and sizes,so that—once container 114 is filled with media 112 and controller116—the seam is located as shown in FIG. 15, partially up the side wall.Of course, it is contemplated by the present disclosure for container114 to have seam 170 at any location provided that cylindrical wallpanel 164 lacks any seams that run along the primary flow direction (A).Further, it is contemplated that multiple materials can be used forpanels 164, 166 such that device 110 includes multiple seams 170 atdifferent locations.

Moreover, it should be recognized that container 114 is described by wayof example has having panels 164, 166, and 168 formed separately thenjoined together. However, it is contemplated by the present disclosurefor at least panels 164 and 168 of container 114—and in some embodimentpanel 168—to be formed from single panel such as those made using knowncircular knitting techniques.

Retaining panel 168 is secured to bottom panel 166 so as to form apocket 172 into which controller 116 is secured. In an embodiment,controller 116 is held in pocket 172 by the elastic properties ofcontainer 114. In the illustrated embodiment, retaining panel 168 has anouter edge 174 and an inner edge 176—where the outer edge is secured tobottom panel 166 and the inner edge remains unsecured to the bottompanel forming pocket 172 therebetween.

Retaining panel 168 has an unstretched outer diameter—defined at outeredge 174—that is smaller than the outer diameter—defined at outer edge150—of the controller 116. In this manner, insertion of retaining panel168 into pocket 172 stretches bottom and retaining panels 166, 168 tohold controller 116 in pocket. Retaining panel 168 has an unstretchedouter diameter that is at least 10% less that the outer diameter ofcontroller 116, or may be at least 40% less, or may be at least 60% lessbeing desired. In one embodiment, retaining panel 168 has an unstretchedouter diameter of 110 mm and finds use with controller 116 having anouter diameter of 192.5 mm. Thus, effect of installing controller 116into pocket 172 is that the portion of bottom panel 164 inside of outeredge 174 of retaining panel 168 is also stretched at least 10%, or maybe at least 40% less, or may be at least 60% less being desired.Furthermore, device 110 is configured so that the stretch of bottompanel 166—at least in the region of controller 116—is independent of theamount of resin in container 114 and/or the depletion level of the resinin the container.

In some embodiments, container 114 can be assembled by turning thecontainer inside out, installing controller 116 in pocket 172, thenreturning the container to its normal orientation before filling withmedia 112 and closing with closure 118.

When controller 116 is installed in pocket 172, retaining panel 168 canhave an inner diameter, defined at inner edge 176, that is small enoughto ensure that openings 162 and central opening 156 in the controllerremain unrestricted by the retaining panel. However and depending on theflow restriction characteristics desired, it is contemplated by thepresent disclosure for inner edge 176 cover openings 162, and in otherembodiments central openings 156. Simply, it is contemplated by thepresent disclosure for retaining panel 168 to—in its most restrictiveform—to have a sufficiently sized opening to allow insertion ofcontroller 116.

Advantageously, device 110 via the interconnection of container 114 andcontroller 116 is configured to stretch bottom panel 166 consistently toa predefined amount. Bottom panel 166 is the area of entry for waterinto device 110. The amount of stretch applied to the fabric of bottompanel 166 effects the porosity of this entry point. It has beendetermined by the present disclosure that stretching bottom panel 166consistently to the predefined amount provides maximization of media 112utilization by providing a lowest level of fluid restrictioninto/through device 110 at the water entry side.

It should be recognized that device 110 is disclosed above by way ofexample as having controller 116 in bottom panel 166—where that panel isthe water entry side of the device. However, it is contemplated by thepresent disclosure for device 110 to be arranged so that bottom panel166 is the water exit side. Further, it is contemplated by the presentdisclosure for device 110 to have controller 116 integrated at both thewater entry and water exit side. In short, device 110 can havecontroller 116 at the water entrance side (which can be the bottom ortop of the device), at the water exit side (which can be the bottom ortop of the device), or at both the water entrance and exit sides.

Without wishing to be bound by any particular theory, it is believedthat compressive forces on media 112 minimizes movement of theindividual resin beads within container 114 before, during, in betweenuses, and after use. It is believed that maintaining of media 112 in acompressed state within container 114 and/or system 20 as the mediachanges in volume due to depletion, at least in part, maximizes the useor consumption of media. However, this can be made particularlydifficult as it has been determined by Applicant that media 112, whendepleted has a reduced volume. In some embodiments, media 112 canexperience a reduction in volume of up to 20%—but of course more or lessvolume reduction is contemplated by the present disclosure.

In some embodiments, device 110 is formed of material sufficient tomaintain media 112 under compression even after being used or spent.

Additionally, device 110 is configured so that controller 116 maintainsthe predetermined stretch of bottom panel 166—at least in the region ofthe controller—after media 112 has been used or spent.

Accordingly, purification device 110 of the present disclosure—namelymedia 112, container 114, and integral flow controller 116—has beenfound to provide a simple, yet effective way to improve the utilizationof the media while remaining easy to load and unload from system 20.

Referring to FIGS. 24A-G, FIGS. 25A-G, FIGS. 26A-G, and FIG. 27illustrate the results of resin usage tests that were performed todetermine the water flow through the system and, thus, to compare mediausage. A total of five tests are compared in FIG. 27, these tests areidentified as Test 1, Test 1 a, Test 2, Test 2 a, and Test 3 with theresults being reported in both liters and grains.

Test 1 and Test 2 are simply reported herein as they were performed inApplicant's own U.S. Ser. No. 14/684,071. Test 1 a is a retest of theTest 1, Test 2 a is a retest of Test 2. It is noted that the differencein results between Tests 1/1 a and 2/2 a are believed to be attributableto differences in the resin. Thus, Test 1 a, 2 a, and 3 were performedusing resin from the same manufacturing lot to reduce the impact ofresin differences—manufacturer-to-manufacturer and/or lot-to-lot—on theresults of FIG. 27.

During the Test 1 a, the pure water system used is Applicant'scommercially available HydroPower® system—which includes a staticdiffuser inside of the system and a container, which is described inApplicant's own U.S. Ser. No. 14/684,071.

During Test 2 a, the pure water system used was the dynamic diffusershown in FIG. 23 of and the system shown in FIG. 1 of Applicant's ownU.S. Ser. No. 14/684,071.

During the Test 3, system 20 of FIG. 1 was used together with waterpurification device 110 of FIGS. 15-23, which includes the integralcontroller 116.

Thus, the three tests performed compare the results of a static diffuser(Tests 1/1 a), a dynamic diffuser (Tests 2/2 a), and integrated flowcontroller 116 (Test 3).

During Tests 1 and 2, the media was a mixed bed resin of a colorchanging resin commercially available from Purolite®. During Tests 1 a,2 a, and 3, the media was a mixed bed resin of a color changing resincommercially available from Resin Tech, Inc. sold as part number MBD30.In all tests, the fresh or un-used color changing resin has a dark (e.g.purple) color that lightens to a light (e.g., yellow) color whendepleted or used. It is noted that the darker yellow regions in thefigures do not represent different resin usage, but rather is anindication of water saturation.

Water of a known particulate level, namely 400 parts per million (ppm),was fed to the systems at a known flow rate of about 6 liters perminute. Since it is impossible to dictate the quality of the incomingwater, the water used during the tests was controlled to 400 ppm usingknown chemical injection techniques that combines tap water with amixture of 4 parts calcium chloride and 1 part magnesium sulfate.

Water exiting the systems was tested for its particulate load with thetest being stopped when the media within the system was no longer ableto provide water of a desired particulate level—in this case 20 ppm. Thewater flow was then stopped and system was placed in a freezer to freezethe resin of media in position. After frozen, the systems were cut awayto provide the media in a solid mass (FIGS. 24A, 25A, 26A). These solidmasses were then sectioned at regular intervals, namely into sixintervals in FIGS. 24B-24G, 25B-25G, and 26B-26G, respectively.

It is noted that the sections were approximately defined at the commonlocations along the flow direction such that FIGS. 24B, 25B, and 26Beach represent approximately a common location, FIGS. 24C, 25C, and 26Ceach represent approximately a common location, and so on. In this way,comparison of the resin usage can be seen by visual comparison of thetest results at these common locations.

It is also noted that the testing in all of these tests include normalvariations that can be expected when measuring the removal of solidsfrom running water on an ionic basis. The testing was performed tominimize differences by holding constant attributes such as, but notlimited to, resin type/lot, temperature, incoming water quality, flowrates, and others.

FIG. 24A illustrates the prior art media as a solid mass of frozen mediaafter completion of Test 1 a and before being sectioned. FIGS. 24B-24Gshow the solid mass of media after completion of Test 1 a and insectioned form. Here, FIG. 24B represents sections at the bottom of thesolid mass, namely where the test water entered the container.Conversely, FIG. 24G represents the section of the frozen media at thetop of the solid mass, namely where the test water exited the container.Thus, the flow direction (F) of water through the media during Test 1 awas from the bottom (FIG. 24B) to the top (FIG. 24G).

It can be seen that the media utilization when using the prior artstatic diffuser plate in FIG. 24B-24G initially results all media beingspent in the first section of FIG. 24B, with a ring of unspent media inthe second section of FIG. 24C, followed by a circular dark (purple)circle of unspent media throughout the center section and the light(yellow) outer rim of spent media in the next two sections of FIGS.24D-24E, and then by increasing amounts of unspent media remaining inthe four upper sections of FIGS. 24F-24G with not enough absorption ofthe media having occurred at the water exit so as to perceptually changethe color of the media.

From FIG. 27, it can be seen that Test 1 a provided 320 liters of 10 ppmwater and 350 liters of 20 ppm water. Again, increases in the amount ofpurified water between Test 1 and Test 1 a are attributed to differencessuch as, but not limited to, the resin being tested, water being tested,and equipment used.

FIG. 25A illustrates the prior art media as a solid mass of frozen mediaafter completion of Test 2 a and before being sectioned. FIGS. 25B-25Gshow the solid mass of media after completion of Test 2 a and insectioned form. Here, FIG. 25B represents sections at the bottom of thesolid mass, namely where the test water entered the container.Conversely, FIG. 25G represents the section of the frozen media at thetop of the solid mass, namely where the test water exited the container.Thus, the flow direction (F) of water through the media during Test 2 awas from the bottom (FIG. 25B) to the top (FIG. 25G).

It can be seen that the media utilization provided by the prior artdynamic diffuser in FIG. 25B-25G initially results in all media beingspent in the first two sections of FIGS. 25B-25C, followed by a circulardark (purple) circle of unspent media throughout the center section andthe light (yellow) outer rim of spent media in the third section of FIG.25D, and then by increasing amounts of unspent media remaining in thethree upper sections FIG. 25E-25G with not enough absorption of themedia having occurred at the water exit so as to perceptually change thecolor of the media.

From FIG. 27, it can be seen that Test 2 a provided 353 liters of 10 ppmwater and 384 liters of 20 ppm water. Again, increases in the amount ofpurified water between Test 2 and Test 2 a are attributed to differencessuch as but not limited to, the resin being tested, water being tested,and equipment used. As discussed in the prior art and again illustratedin FIG. 27, the dynamic diffuser provides better utilization of themedia than a static diffuser.

Unfortunately, it has been determined by the present disclosure thatdynamic diffusers of the prior art—although effective at increasingresin utilization—are not optimal. In some examples, the dynamicdiffusers prevent or hamper draining of water from the system after use.This can greatly increase the draining time during resinreplacement—negatively effecting the ability of the user to quicklychange the resin.

In other examples, the dynamic diffusers are difficult to maintain in adesired horizontal position during use, resulting in jams and leakagepast the diffuser.

In still other examples, the user must manually move the dynamicdiffuser within the system such as during installation or removal orwhen moving to a lowered position when replacing the media—which canprove difficult particularly in instances where multiple containers areused.

In still more examples, the manufacturing tolerances of such prior artdynamic diffusers have proven difficult to maintain a moving sealbetween the dynamic diffuser and the inner wall of the tank—whileincreasing the cost of such prior art diffusers.

Additionally, it has been found by the present disclosure that the priorart dynamic diffuser can provide restriction of flow through the systemsufficient to reduce usable pressure of the outgoing water. For example,in instances when prior art systems are used with normal tap waterpressure and used to clean exterior windows of multistory buildings, thedynamic diffuser can result in water flow restrictions that limit theuse of the system by one or two stories as compared to prior art systemswithout such diffusers or systems of the present application having theintegral flow controllers.

Advantageously, the integral flow controllers overcome these anotherother deleterious effects of the prior art while providing equalperformance. Further, the integral flow controllers require lesscomponents—lacking the o-ring, mesh, and other components of the priorart.

FIG. 26A illustrates media as a solid mass of frozen media aftercompletion of Test 3 and before being sectioned. FIGS. 26B-26G show thesolid mass of media after completion of Test 3 and in sectioned form.Here, FIG. 26B represents sections at the bottom of the solid mass,namely where the test water entered the container. Conversely, FIG. 26Grepresents the section of the frozen media at the top of the solid mass,namely where the test water exited the container. Thus, the flowdirection (F) of water through the media during Test 3 was from thebottom (FIG. 26B) to the top (FIG. 26G).

It can be seen that the media utilization when using integral controller116 of the present application initially results in all media beingspent in the first three sections of FIGS. 26B-26D, followed byincreasing amounts of unspent media remaining in the three uppersections FIG. 26E-26G with not enough absorption of the media havingoccurred at the water exit so as to perceptually change the color of themedia.

From FIG. 27, it can be seen that Test 3 provided 324 liters of 10 ppmwater and 364 liters of 20 ppm water. Comparing Test 3 to Test 1 a, itcan be seen that the integral flow controller 116 of the presentapplication provides about 25% more purified water at 10 ppm and about20% more at 20 ppm then the static diffuser of the prior art. ComparingTest 3 to Test 2 a, it can be seen that the integral flow controller 116of the present application provides about 9% less purified water at 10ppm and about 5% less purified water at 20 ppm as the dynamic diffuserof the prior art. However, the integral flow controller 116 avoids,overcomes, and/or mitigates the issues related to the use of dynamicdiffusers. In short, device 110 of the present application provides onlyslightly less purified water as the prior art dynamic diffusers, butdoes so in manner that is significantly easier to use and manufacture,costs less to manufacture, and does not impact functionality (e.g.,allows for 1-2 additional stories of washing pressure as compared to theprior art dynamic diffusers).

It should also be noted that the terms “first”, “second”, “third”,“upper”, “lower”, and the like may be used herein to modify variouselements. These modifiers do not imply a spatial, sequential, orhierarchical order to the modified elements unless specifically stated.

While the present disclosure has been described with reference to one ormore exemplary embodiments, it will be understood by those skilled inthe art that various changes may be made and equivalents may besubstituted for elements thereof without departing from the scope of thepresent disclosure. In addition, many modifications may be made to adapta particular situation or material to the teachings of the disclosurewithout departing from the scope thereof. Therefore, it is intended thatthe present disclosure not be limited to the particular embodiment(s)disclosed as the best mode contemplated, but that the disclosure willinclude all embodiments falling within the disclosure.

What is claimed is:
 1. A pure water system, comprising: a tank, a cover,an inlet port, and an outlet port configured to define a reservoir; anda purification device received in the reservoir so that water can flowinto the inlet port, through the purification device, and out of theoutlet port along a primary axis of flow, wherein the purificationdevice comprises a porous container, purification media retained in theporous container, and a flow controller.
 2. The pure water system ofclaim 1, wherein the porous container is a porous elastic container. 3.The pure water system of claim 2, wherein the flow controller isconfigured and arranged within the porous container to stretch a waterentry side of the porous elastic container at least 10% from anunstretched state.
 4. The pure water system of claim 1, wherein theprimary axis of flow is an upward flow direction.
 5. The pure watersystem of claim 1, wherein the flow controller is at a water entry sideof the porous container, the water entry side being proximate the inletport.
 6. The pure water system of claim 1, wherein the purificationmedia is compressibly retained in the porous container.
 7. The purewater system of claim 1, wherein the flow controller is completelyinside the porous container.
 8. The pure water system of claim 1,wherein the flow controller is a rigid disk.
 9. The pure water system ofclaim 1, wherein the flow controller is made of at least one ofpolypropylene (PP), acrylonitrile butadiene styrene (ABS), polystyrene(PS), polyvinyl chloride (PVC), thermoplastic elastomer (TPE), andstainless steel.
 10. The pure water system of claim 1, wherein the flowcontroller comprises a pivot preventer configured to maintain the flowcontroller perpendicular to the primary flow axis.
 11. The pure watersystem of claim 1, wherein the flow controller has a frustoconicalshape.
 12. The pure water system of claim 1, wherein the flow controlleris installed in a pocket of the porous container.
 13. The pure watersystem of claim 1, wherein the flow controller has one or more ribsdefined on a lower face facing a portion of the porous container. 14.The pure water system of claim 1, wherein the flow controller has acentral opening that is between 10% and 90% of an outer diameter theflow controller.
 15. The pure water system of claim 1, wherein the flowcontroller includes a plurality of water flow openings.
 16. The purewater system of claim 1, wherein the flow controller has a zone oflowest restriction at a central region.
 17. A method of purifying watercomprising: passing water through a pure water system, the pure watersystem comprising a tank, a cover, an inlet port, and an outlet portconfigured to define a reservoir, and a purification device received inthe reservoir so that the water from the inlet port, through thepurification device, and out of the outlet port along a primary axis offlow, wherein the purification device comprises a porous container,purification media retained in the porous container, and a flowcontroller.